CWI

PRACTICE
QUESTIONS
CWI PRACTICE QUESTIONS
A written qualified welding procedure prepared to provide
direction for making production welds to Code
requirements.

a. Procedure Qualification Record

b. Welder Performance Qualification
c. Welding Procedure Specifications
d. None of the above

ANSWER: B
CWI PRACTICE QUESTIONS
A record of variables recorded during the welding of the
test coupons. It also contains the test results of the
tested specimens. Recorded variables normally fall within
a small range of the actual variables that will be used in
production welding.

a. Procedure Qualification Record

b. Welder Performance Qualification
c. Welding Procedure Specifications
d. None of the above

ANSWER: A
CWI PRACTICE QUESTIONS
The record of welder qualification tests and shall
include the essential variables, type of test and the
ranges qualified.

a. Procedure Qualification Record

b. Welder Performance Qualification
c. Welding Procedure Specifications
d. None of the above

ANSWER: B
CWI PRACTICE QUESTIONS
These variables if changed, will be considered to
affect the mechanical properties of the weldment
and therefore shall require requalification of the
WPS

a. Essential Variables
b. Supplementary Essential Variables
c. Nonessential Variables
d. None of the above

ANSWER: A
CWI PRACTICE QUESTIONS
Required for metals for which the referencing code
or standard requires toughness tests in addition to
the essential variables for each welding process.

a. Essential Variables
b. Supplementary Essential Variables
c. Nonessential Variables
d. None of the above

ANSWER: B
CWI PRACTICE QUESTIONS
These variables if changed, as described in the
specific variables, may be made in the WPS
without requalification

a. Essential Variables
b. Supplementary Essential Variables
c. Nonessential Variables
d. None of the above

ANSWER: C
CWI PRACTICE QUESTIONS
Which code gives prequalified status to certain
weld joint configurations?

a. API 1104
b. AWS D1.1
c. AWS B2.1
d. ASME IX

ANSWER: B
CWI PRACTICE QUESTIONS
How does a welder become certified?

a. certification can only be obtained by taking a weld test given

by a CWI
b. Graduating from a weld school
c. Having documented proof of 5 years in welding industry
d. Documenting successful completion of a weld test according
to the requirements of an applicable standard

ANSWER: D
CWI PRACTICE QUESTIONS
AWS D1.1 has a prequalified list of welding
processes, which of the following is not a
prequalified process?

a. SMAW
b. GTAW
c. GMAW-S
d. FCAW

ANSWER: C
CWI PRACTICE QUESTIONS
Which of the following is not a valid qualification of
the weld procedure?

a. Prequalification
b. Welding test coupons
c. Mock-up tests
d. Writing a procedure only

ANSWER: D
CWI FUNDAMENTAL EXAM QUESTIONS
Which GMAW metal transfer mode results in the least
amount of penetration?

a. globular
b. short circuiting
c. pulsed spray
d. None of the above

ANSWER: B
CWI PRACTICE QUESTIONS
The melting point of carbon steel is approximately:

a. 2250oF
b. 2375oF
c. 2780oF
d. 3000oF

ANSWER: C
CWI PRACTICE QUESTIONS
Which of the following gas(es) is commonly used
as a shielding gas for GTAW?

a. argon
b. carbon dioxide
c. oxygen
d. argon/CO2

ANSWER: A
CWI PRACTICE QUESTIONS
The technique which does not aid in reducing
residual stress is:

a. peening
b. Vibratory stress relief
c. External restraint
d. preheating

ANSWER: C
CWI PRACTICE QUESTIONS
Which of the factors listed below has the least
amount of effect on the residual stress and
distortion that results from welding?

a. heat input
b. tensile strength
c. welding position
d. phase change

ANSWER: C
CWI PRACTICE QUESTIONS
When a metal is alloyed, how are the atoms of the
alloy incorporated into the original metal lattice
structure?

a. by inclusion or exclusion
b. by becoming martensitic
c. substitutionally or interstitially
d. by casting

ANSWER: C
CWI PRACTICE QUESTIONS
In general, which of the following is not commonly
used as a semiautomatic process?

a. GMAW
b. FCAW
c. SAW
d. SMAW

ANSWER: D
CWI PRACTICE QUESTIONS
During tempering, as the temperature increases,
which of the following is correct?

a. hardness increases
b. Hardness decreases
c. Strength increases
d. Elongation decreases

ANSWER: B
CWI PRACTICE QUESTIONS
Of the following, which is not a type of metal
transfer in GMAW?

a. spray
b. Short circuitting
c. globular
d. Open circuiting

ANSWER: D
CWI PRACTICE QUESTIONS
Of the following tests, which can be used for the
actual determination of a material’s toughness?

a. Charpy test
b. Magnetic Particle Test
c. Tensile Test
d. Bend Test

ANSWER: A
CWI PRACTICE QUESTIONS
Which of the following represents the proper eye
protection for SAW?

a. A welding helmet with filter lens of the appropriate shade

b. Clear safety glasses
c. No eye protection is required because there is no visible arc
d. Tinted safety glasses
e. A full face shield with a shade #5 minimum

ANSWER: D
CWI PRACTICE QUESTIONS
An E7018 SMAW electrode exhibits which of the
following characteristics?
a. Low hydrogen; use on AC only; iron powder
b. Low hydrogen; use on AC and DCEN
c. Low hydrogen; AC and DCEP; iron powder
d. Rutile; DCEP
e. Rutile; DCEP; iron powder

ANSWER: C
CWI PRACTICE QUESTIONS
A thermal treatment that follows quenching and
restores some of the metal’s ductility is referred to
as:
a. Stress relief
b. Tempering
c. Hardening
d. Normalizing
e. Postheat

ANSWER: B
CWI PRACTICE QUESTIONS
Which of these methods is most often used to
eliminate the high residual stress by welding?

a. prebending
b. Shot blasting
c. Quenching rapidly after welding
d. Postweld heat treating
e. Preheating

ANSWER: D
CWI PRACTICE QUESTIONS
The physical principle that permits the migration of
liquid penetrant into very fine surface
discontinuities is:

a. Magnetic permeability
b. Optical fluorescence
c. Capillary action
d. Emulsification
e. Solubility

ANSWER: C
CWI PRACTICE QUESTIONS
In SMAW, an increase in arc length results in:

a.Increased current; increased voltage

b.Decreased current; increased voltage
c.Increased heat input; decreased voltage
d.Decreased current, decreased voltage
e.Decreased current; increased heat input

ANSWER: B
CWI PRACTICE QUESTIONS
Weld inspection report should always:

a.Be completed in ink, or typewritten and signed

b.Be done in pencil so mistakes can be erased
c. Be filled out only if the weld is rejected
d. retyped by a clerk so that everything is
readable
e.Include the welder’s identification
ANSWER: A
CWI PRACTICE QUESTIONS
The ability to be cyclically loaded without failing is
related to which of the following properties of a
metal?
a. hardness
b. toughness
c. tensile strength
d. fatigue strength
e. ductility

ANSWER: D
CWI PRACTICE QUESTIONS
Which of the following is truly a volumetric test
method?

a. RT
b. UT
c. VT
d. MT
e. PT

ANSWER: B
CWI PRACTICE QUESTIONS
Use of preheat will result in:

a. a faster cooling rate and wider heat-affected zone

b. a faster cooling rate and narrower heat-affected
zone
c. a slower cooling rate and wider heat-affected zone
d. a slower cooling rate and narrower heat-affected
zone

ANSWER: C
CWI PRACTICE QUESTIONS
The material property that best describes its ability
to withstand a static load is :
a. hardness
b. toughness
c. tensile strength
d. fatigue strength
e. torsional strength

ANSWER: C
CWI PRACTICE QUESTIONS
The welding variables used to calculate heat input
are:
a. voltage and current
b. current and travel speed
c. voltage, current and travel speed
d. travel speed, preheat temperature and voltage
e. voltage, current and preheat temperature

ANSWER: C
CWI PRACTICE QUESTIONS
In general, an increase in the carbon equivalent of
a carbon steel will result in an in increase in its:
a. ductility
b. hardness
c. defects
d. toughness
e. all of the above

ANSWER: B
CWI PRACTICE QUESTIONS
As the temperature of the base metal is increased:

a. impact strength decreases

b. tensile strength decreases
c. ductility decreases
d. hardness increases
e. tensile strength increases

ANSWER: B
CWI PRACTICE QUESTIONS
A weld inspection plan should be developed:

a. before welding begins

b. during welding
c. after welding is completed
d. before shipping the work
e. only when there is a problem

ANSWER: A
CWI PRACTICE QUESTIONS
Dwell time is a term associated with which NDE
method?
a. MT
b.PT
c.RT
d.ET
e.UT

ANSWER: B
CWI PRACTICE QUESTIONS
The material property expressed in terms of an
endurance limit is:
a. fatigue strength
b.toughness
c.Tensile strength
d. ductility
e. hardness

ANSWER: A
CWI PRACTICE QUESTIONS

The welding inspector is usually not

responsible for which of the following?
a. checking for proper electrode storage
b. verification of a welder’s qualification
c. witnessing all repairs
d. reinspecting repairs
e. checking fit up

ANSWER: C
CWI PRACTICE QUESTIONS

The last digit of a SMAW electrode

designation is an indication of:
a. tensile strength of the weld deposit
b.Position of the welder is qualified to weld in
c.Operating characteristics
d. Impact strength of the weld deposit
e.Position suitable for electrode use

ANSWER: C
CWI PRACTICE QUESTIONS

For SMAW electrode designation E60X3, the X

refers to:
a. tensile strength of the weld deposit
b.Position in which the electrode can be used
c. type of coating
d. The recommended type of current
e. Flux chemistry

ANSWER: B
CWI PRACTICE QUESTIONS

Which of the following methods is most likely to

use a transducer to scan for flaws?
a. RT
b. MT
c. UT
d. PT
e. VT

ANSWER: C
CWI PRACTICE QUESTIONS

For plain carbon steels, how are hardness and

tensile strength related?
a. increase hardness; decrease tensile strength
b. increase hardness; increase tensile strength
c. decrease hardness; increase tensile strength
d. hardness and tensile strength can both be increased
by tempering
e. hardness and strength are not related

ANSWER: B
CWI PRACTICE QUESTIONS

Hydrogen in the molten weld metal can cause:

a. undercut and overlap

b. cracking and porosity
c. incomplete penetration and incomplete fusion
d. porosity and slag inclusions
e. hydrogen will diffuse during welding and will not
cause problems

ANSWER: B
CWI PRACTICE QUESTIONS
Which of the following results from improper termination of the
SMAW electrode and shrinking of the molten weld pool during
welding?
a. porosity
b. slag inclusions
c. delayed cracking
d. crater cracking
e. incomplete fusion

ANSWER: D
CWI PRACTICE QUESTIONS

Entrapped slag can result when using all of the following

except:
a. SMAW
b. SAW
c. FCAW
d. ESW
e. GMAW

ANSWER: E
CWI PRACTICE QUESTIONS

The rapid quenching of a high carbon steel from the

austenitizing range will result in the formation of:
a. pearlite
b. martensite
c. cementite
d. ferrite
e. austenite

ANSWER: B
CWI PRACTICE QUESTIONS
When an austenitized carbon steel is cooled to room
temperature, an increase in the cooling rate will result
in:
a. an increase in hardness and a decrease in ductility
b. an increase in tensile strength and a decrease in
hardness
c. a decrease in tensile strength and an increase in
hardness
d. an increase in ductility and a decrease in hardness
e. a decrease in hardness and an increase in ductility
CWI PRACTICE QUESTIONS
The heat treatment in which a carbon steel’s temperature is
raised to the austenitizing range, held for a prescribed time and
then allowed to cool to room temperature while remaining in the
furnace is referred to as:

a. stress relief
b. annealing
c. normalizing
d. tempering
e. austenitizing
ANSWER: B
CWI PRACTICE QUESTIONS
Which of the following is least affected by the surface finish of
the specimen?

a. tensile strength
b. fatigue strength
c. impact strength
d. nick break test
e. macroetch

ANSWER: D
CWI PRACTICE QUESTIONS
The heat treatment in which a carbon steel’s temperature is
raised to the austenitizing range, held for a prescribed time and
then allowed to cool to room temperature in still air is referred
to as:

a. austenitizing
b. normalizing
c. annealing
d. quenching
e. tempering
ANSWER: B
1. Answer: C

WPS or welding procedure specification provides the qualified direction or procedure for making
production welds in accordance to code requirements.

2. Answer: A

PQR or procedure qualification record is the record of the test results and the parameters used
in creating the qualified production weld. It qualifies the weld but not the welder.

3. Answer: B

WPQ or welder performance qualification provides the qualification tests and record of variables
use to qualify a welder with a code/standard.

4. Answer: A

Essential variables affect the mechanical properties. Changing these variables will require
requalification of the WPS

5. Answer: B

Supplementary essential variables will be required when toughness tests are required per the
referencing construction code.

6. Answer: C

Nonessential variables as described in the specific variables that can be changed without
requalification.

7. Answer: B

From the choices only AWS D1.1 gives guidelines on how to prequalify weld joint, that is
qualification of the weld without test coupons.

8. Answer: D

Different codes require different requirements on the qualification of a welder. For example
ASME IX has different sets of essential variables that a welder must be qualified and so as AWS
D1.1. All of the choices are incorrect.

9. Answer: C

GMAW-S cannot be prequalified because of the insufficient current to create a satisfactory weld.
Low current and low heat input welding process is more susceptible to defects. This does not
mean you cannot use this process, it just needs to be qualified.
10. Answer: D

Writing a procedure only does not automatically qualify a weld procedure. Prequalification can
be done in accordance to some codes but not all. The term here “only” is a giveaway that

11. Answer: B
GMAW has different modes of transfer.
Globular transfer occurs at lower voltage and current but at higher levels than short-
circuiting. This enables deeper penetration due to the amount of current and heat input.
Pulse transfer varies the current during the process which enables all-position welding
because of more control over the weld. It can also be used for thinner metals which cannot
be applicable for conventional spray.
Short circuiting has the lowest heat input out of all the GMAW modes of tranfer because of its low
voltage and current setting.

12. Answer: C

If you would look at the iron-carbon phase diagram below, the temperature in which carbon
steel turns into molten liquid is approximately 2800 deg. F, so the answer here is 2780 deg. F

13. Answer: A
 Argon is the most common because not only amongst the choices that it is the only inert gas but
it is also the cheapest among all the shielding gas hence it is the most commonly used shielding
gas. Shielding gas can also be used as a mixture that is why you see the argon CO2 as a choice
here, these mixtures of shielding gas will provide a different purpose than when used singularly.
ASME Section II Part C not only provides information about the filler metals and electrodes but
for the shielding gases as well.

14. Answer: C
Peening is a form of mechanical heat treatment in the form of hammer blows.
Vibratory stress relief also is a kind of mechanical heat treatment to reduce the residual stresses.
Preheating enables the material to resist rapid cooling hence prevent distortion and residual
stresses.
External restraint does not have anything to do in reducing residual stress and may help distort it
because metals when heated tends to expand, having external restraints will just add undue
thermal stresses on the metal.

15. Answer: C

Heat input has an effect on the residual stress because it affects the rate of cooling of the metal,
the faster the cooling, the more brittle the material gets.

Tensile strength not only denotes strength but also the hardness of the material, the higher the
tensile strength, hence more carbon, the more stringent postweld heat treatment procedure will
be used to remove the residual stresses

Phase change refers to the change of the property of the metal and when this happens you can
guarantee that distortion and residual stress already has affected the material.

Welding position on the other hand does not directly affect the heat input because no matter
what the position is, the heat input parameters like current, polarity and voltage must be
followed in accordance with the specifications.

16. Answer: C
Inclusion or extrusion does not refer to the incorporation of the atoms to the lattice structure.
Becoming martensitic enables the material to become brittle when the metals are rapidly
cooled.
Casting is a form of manufacturing process. Interstitial alloying or substitutional alloying refers to
the incorporation or addition of the atoms to the original lattice structure.

17. Answer: D
 GMAW, FCAW, SAW all has features of automatically feeding the wire into the electrode gun thus
being a semiautomatic process. Only SMAW can be called as a manual process because of the
manual replacement of the electrode. It is also known as MMA or Manual Metal Arc welding.

18. Answer: B
After tempering, the hardness of the metal decreases. This occurs as a consequence of
controlling the effects of rapid-cooling of the metal which makes the metal brittle.

19. Answer: D
Spray, globular and short-circuitting are all types of metal transfer in GMAW. Open circuiting is
not one of them.

20. Answer: A

Impact tests determine the material’s toughness. Only letter A Charpy test is a kind of impact
test amongst the choices.
21. Answer: D

So, unlike the other welding processes, submerged arc welding process has high operator appeal
because the lack of a visible arc allows the operator to control the welding without the need for a filter
lens and other heavy protective coating. Since the flux, covers the molten pool of metal, the arc is not
visible and lesser smoke is generated unlike other welding processes. With this, you still need to protect
your eyes because of the flux but no specific tint protection is needed, hence the answer is letter D. In
this question you need to be familiar of two aspects of welding inspection, safety and the welding
process itself.

22. Answer C

E7018 is a low hydrogen electrode so by process of elimination, letter D and E can be ruled out. If the
electrode ends with the digit 5,6 or 8 then it can be concluded that that electrode is low hydrogen.
This leaves us to the familiarity of this table below. The digit 8 can be used for AC and DCEP with 25-45%
iron powder. That leaves us with letter C which is the answer.

23. Answer: B

Stress relief is a general heat treatment term that removes residual stresses of the metal

Hardening is synonymous with quenching where the metal is subject to quick cooling in order to create
tool steels which are very hard metals used for fabrication equipment.

Normalizing is the heat treatment process where the metal is cooled in still air which results in a middle
range of ductile and brittle material.

Postheat is a term also used to relieve residual stress of the metal and is applied after the welding
process and normally is a thermal process.

Which leaves us to letter B the answer, tempering restores some ductility which follows after quenching,
since quenching’s intention is to rapidly cool the metal to make it harder but will lose some of its
ductility.

24. Answer: D

Prebending refers to the parts before welding to counteract shrinkage by introducing pre-stressing.

Shot blasting is a form of surface preparation technique used to remove debris and irregularities
example of this is sandblasting.

Quenching rapidly after welding will result in the formation of martensite, which a grain structure that
promotes brittleness.

Preheating promotes appropriate grain structure by preventing rapid cooling of the metal but the
question here is eliminate high residual stress by welding which only meant that the stresses produced
after welding so this leaves us with the answer letter D postweld heat treating which the primary
purpose is to eliminate residual stress due to the welding.

25. Answer: C

Now this concept is the basis of dye penetrant testing wherein after the penetrant went in to the pores
or crevices of the welds and after applying the developer it reveals whatever discontinuity the weld
might have. This is by the concept of capillary action where the liquid ascends through a slim or
permeable substance. The answer here is letter C.

26. Answer: B

This question can best be explained with a graph. As a welder increases arc length, the resistance in the
welding circuit also increases because of the larger gap between the electrode and the base metal. As
seen here in the voltage-current graph of SMAW, the increase in resistance cause a slight decrease (10%)
in the current flow across the gap, this decrease results in a significant increase in voltage, in this
example 32% supplied by the power source, which limits the drop in current. So from the choices below,
the answer is B.
 27. Answer: A

Letter B is not advisable since temporary written reports are prone to ineligibility later on. Weld report is
done whether the weld is accepted or rejected, so letter C is not the answer. The weld inspection report
shall be done by the one who inspected the weld, preferably the one in charge of the welding quality
control program or a CWI, it can be retyped by a clerk but is not necessary, since the question specifies
“ALWAYS”, this is not always the case. The weld inspection report does not necessarily indicate the
welder’s identification, the report may contain the welder ID but not always needed.

28. Answer: D

Hardness is the resistance of a material against deformation. Toughness is the ability of the material to
absorb energy without fracture and can be measured through impact testing. Tensile strength is the
maximum load a material can withstand before fracture, this is before the end of the stress-strain curve
as seen.

Ductility is synonymous to toughness, it is the ability of a material to deform plastically in tension or

shear without fracture.

This leaves us to the answer fatigue strength which pertains to the resistance of a body against cyclic
forces.
 29. Answer: B

RT is a type of volumetric test but with limitations, VT is limited to surfaces only while PT and MT can
detect surface and subsurface discontinuities. UT is truly a volumetric test because it can do RT’s
limitations.

30. Answer: C

Preheat helps prevent quick cooling of metals and promotes finer grain structure and helps against
embrittlement. By this definition, the best answer that fits this description is letter C, it will result in
slower cooling rate and wider heat affected zone since greater heat input is present in the base metal
due to the preheating.

31. Answer: C

The ability to withstand a static load is letter C tensile strength. Strength is defined as the load induced
on a specified area. Let’s take a look at the choices, harndess is the resistance of material against
deformation or indentation. Toughness is the ability of the material to absorb energy without fracture
and can be measured through impact testing. Fatigue strength is the resistance against cyclical loads and
torsional strength is the resistance against twisting loads and moments.

32. Answer: C

Voltage, current and travel speed affects the heat input. Voltage is the amount of electricity induced in
the base metal. The current similar to voltage increases the heat input as the amount of electricity
increases. If you remember, heat input is a function of energy per unit time which the formula of power
is which is voltage times current. The travel speed is measured by the length of the weld deposited in an
amount of time. The faster travel speed, the lesser heat input is produced while a slower travel speed
meaning the electrode is almost staying at one point in the base metal, then the heat input will be
higher. Preheat temperature does not have anything to do with heat input but will have something to do
with the grain structure of the material which then affects the material’s hardness and weldability.

33. Answer: B

An increase in carbon will increase hardness which is the answer letter B. Similarly an increase in carbon
also increase the tensile strength. Hardness and ductility is somehow works opposite to each other so
that’s not the answer. Defects do not have anything to do with this and is caused by several factors such
as workmanship, poor preparation and poor heat treatment. Toughness is the ability of the material to
absorb energy without fracture and can be measured through impact testing.

34. Answer: B

When the temperature of the base metal is increased, the tensile strength decreases. This decrease is
apparent if you see some construction codes such as ASME B31.3, you can see that the strength
decreases if the metal is subjected to higher temperatures. These metals tend to become “softer” so to
speak because of the increased molecular activity due to the high energy input, which is the
consequence of higher temperature. For the choices, impact strength decreases on colder temperatures
not high, that is why you need impact testing when welding at frigid temperatures. Decrease in ductility
is synonymous with a decrease in impact strength. Hardness and tensile strength increase is the direct
opposite of the answer as hardness and tensile strength is almost synonymous to each other.

35. Answer: A

A weld inspection plan should be developed before the welding begins which is the answer. Similar to an
inspection test plan which must be approved prior the actual inspection activity. This inspection plan
also defines the hold points in which the welding inspector will inspect the result of an activity example
the root pass and will not be able to proceed to the next activity related to this until it yielded a positive
result. These hold points will be difficult to implement if these inspection plan are done anytime after
the welding activity begins.

36. Answer: B

Dwell time is closely associated with penetrant testing. Dwell time by definition is the total time that the
penetrant or emulsifier is in contact with the test surface, including the time required for application and
the drain time. This is not applicable for any other tests mentioned in the choices.

37. Answer: A

The property that is expressed in terms of endurance limit is the fatigue strength. For the mechanical
engineers out there, if you can remember the Goodman and Soderberg equation, the endurance limit of
the material is synonymous with the fatigue strength. Looking at the other choices, toughness is the
resistance of material against impact. Tensile strength is the capacity of the material against a given load.
Ductility is the property of material to yield against a load without breaking. Hardness is the resistance of
a material against indentation.

38. Answer: C

Welding inspector is usually not responsible for witnessing every repairs but is responsible for checking if
the repair is satisfactory. Many standards such as API 1104 specifies acceptance criteria for weld repairs
and as such the welding inspector needs to witness and inspect them. Checking for proper electrode
storage is essential since these electrodes have a manufacturer-prescribed storage parameters that is
needed to be followed such as storage temperature to eliminate moisture. Moisture in the electrode can
cause porosity. Verification of welder’s qualification and creation of WPQR or welder qualification record
is a responsibility of a welding inspector as he should determine whether a welder passed a certain code
such as ASME IX, AWS D1.1. Letter D is what I mentioned regarding reinspection of repairs wherein the
inspector must check if the weld repair has satisfactory results. Checking fit-up prior starting a root pass
is a common hold point that the inspector usually does to accomplish the inspection and test plan.

39. Answer: C

The last digit of a SMAW electrode denotes the operating characteristics of an electrode. It denotes the
type of current, the arc characteristics and penetration, the type of covering and slag and percentage of
iron powder used. It also denotes if the electrode is low-hydrogen type or not. Ending with 5,6 and 8
denotes low hydrogen electrodes.
 40. Answer: B

In this question, the X denotes the position in which the electrode can be used. The position in which
these electrodes can be used also depends on its operating characteristics. High deposition electrode
cannot be done on an overhead position since a lot of molten metal will fall to the welder and this is
denoted by digit 2. 1 denotes that the electrode can be used for all position. Digit 3 is no longer used as
a designation so if you see that that is an old designation. 4 denotes welding in a downhill progression.

41. Answer: C

The NDT method most likely to use a transducer to scan flaws is UT or ultrasonic testing. UT makes use
of a transducer attached to an electronic base unit. This machine generates precise electronic pulses
transmitted through a cable to the transducer.

RT is an NDT but makes use of preferential radiation transmission or absorption. Magnetic particle test
or MT utilizes magnetic field to detect surface and subsurface discontinuities. PT or penetrant testing
uses the principle of capillary action to detect flaws. VT is visual inspection where the inspector detects
flaws by using his naked eye and some measuring instruments.

42. Answer: B

As hardness increase, tensile strength increase. A great approximation of this is the formula of BHN is
equal to half of the ultimate strength in ksi. This alone can be a great reminder that as hardness increase,
the tensile strength also increase. BHN is Brinell hardness number which measures the resistance of the
material to indentation which is hardness.

43. Answer: B

Porosity is normally caused by the presence of contaminants or moisture in the weld zone which
decompose due to heat and form gases, and one of them is hydrogen, because our atmosphere contains
moisture. Hydrogen from said decomposition of moisture causes this discontinuity. Other sources of
moisture/hydrogen can be poorly stored electrode, moisture in the base metal and with the shielding
gas as well.
Cracks can also be a result of hydrogen entrapment which propagates in the intergranular or
transgranular structure of the metal.

For the choices:

Undercut is a surface discontinuity which occurs in the base metal directly adjacent to the weld. It is a
condition in which the base metal has been melted away during the welding operation and insufficient
filler metal deposited to adequately fill the resulting depression

Overlap is the protrusion of weld beyond the weld toe or root. It appears though that the weld has
overflowed the joint and laying on the adjacent base metal.
Incomplete penetration is a discontinuity associated only with groove welds. It is a condition where the
weld metal does not extend through the joint thickness.

Incomplete fusion is a weld discontinuity in which fusion did not occur between weld metal and fusion
faces or adjoining weld beads
Letter E is obviously incorrect since hydrogen is one of the cause of cracking and porosity

44. Answer: D

Crater cracking occurs at the termination point of individual weld pass. If the technique used by the
welder to terminate the arc does not provide for complete filling of the molten weld puddle, the result
will be a shallow region or a crater.

For the choices, porosity is the result of moisture or gases in the weld.

Slag inclusions normally occur between the weld and base metal where foreign solid like slag, flux,
tungsten, or oxide.

Delayed cracking is categorized under cold cracks which occur after the metal has cooled to ambient
temperature

Incomplete fusion is a weld discontinuity in which fusion did not occur between weld metal and fusion
faces.

45. Answer: E

Entrapped slag cannot be a result of GMAW because of the absence of flux. All of the processes in the
choices have flux in one form or the other. SMAW, FCAW have flux coating and flux core respectively. This
flux produces slag. SAW has granulated flux that covers the weld pool, ESW is electroslag welding, there
is slag on that process of course. GMAW does not have flux or slag hence the answer. To prevent
atmospheric attack, this process makes use of an external shielding gas like CO2, argon, etc.

46. Answer: B

Very rapid cooling or quenching takes place, there are significant changes in the transformation of a
given steel alloy and if that steel has high enough carbon, martensite will be formed. Martensite exhibits
a body centered tetragonal structure which has high internal energy resulting to high hardness and
tensile strength but comes with low ductility and toughness
For the choices, pearlite forms at a slower cooling rate than bainite and martensite. Bainite forms at a
slower cooling rate than martensite hence with lower ductility than pearlite. One characteristic of bainite
is that it is very difficult to see under the microscope.

Austenite forms at around 1300 degrees F when pearlite and ferrite began to change to austenite but
not all of them, it is at 1550 deg F when the transformation to austenite is complete.

Cementite is formed at similar temperatures when ferrite and pearlite is formed but for higher carbon
content steels.
 47. Answer: A

As a general rule, when austenite is cooled rapidly, hardness increases and ductility decreases because of
the formation of martensite which exhibits lower toughness. Letter B does not normally happen because
hardness normally increase with tensile strength, C is just the opposite of B. Letter D is the opposite of B
and letter E is the direct contrast of the answer.

48. Answer: B

Annealing is the slow cooling of metal to improve its ductility. The slow cooling occurs when this metal is
remained at the furnace until it reaches room temperature. For the choices, stress relief is the general
process of removing residual stress after welding. And the other choices refer to other heat treatment
process aside form austenitizing which is the process of formation of austenite at different temperatures
depending on the material composition.

49. Answer: D

All of the material properties mentioned in the choices are affected by surface finish, any imperfections
in the metal can cause stress concentrations that can affect tensile strength. Surface finish is one of the
factors considered in the calculation of endurance or fatigue strength. Impact strength is greatly affected
by these imperfections, because materials are easier to break when there are surface finish issues.
Macroetch testing is a test that reveals surface imperfections and just like any surface and subsurface
testing, surface finish has an effect on these testing if not properly done like proper surface preparation
etc.
Nick break test is a test for determining the quality of the weld, it breaks open the weld lengthwise.
Surface finish has nothing to do with the inspection and preparation of this test, hence the answer.

50. Answer: B

Normalizing is the cooling of metal from the austenitic range to room temperature in cool air. So for
example in annealing, you cool the material but you leave the furnace open to expose the metal in air,
that is normalizing. Austenitizing is the process of formation of austenite at different temperatures
depending on the material composition. Quenching is the rapid cooling of metal by form of oil or liquid
bath increasing the material’s hardness. Annealing is the slow cooling of metal to room temperature and
tempering is increasing the material’s toughness after quenching.